Closure latch assembly for vehicle closure panel

Abstract

A closure latch assembly for a vehicle closure panel includes a power release gear configured to be driven by a motor in a first direction from an original position to a release position in which the power release gear is driven by the motor in a second direction. The pawl releases the ratchet to allow the ratchet to move to the striker release position and back to the home position in the first direction, whereby when the power release gear returns to the home position, the sensor signals the motor to power off the motor. When the pawl does not release the ratchet, the power release gear is driven by the motor in a second direction opposite the first direction to cause the pawl to release the ratchet, allowing the ratchet to move to the striker release position.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 602,346, filed on November 22, 2023, and the benefit of U.S. Provisional Application Serial No. 63 / 602,351, filed on November 22, 2023, the entire contents of both U.S. Provisional Applications are incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to a power door system for a motor vehicle. More specifically, the present disclosure relates to a power door system equipped with a power latch assembly having a one-way motor and a power release gear having a sensor and a hard stop feature for stopping the power release gear during a normal release process of a pawl relative to a ratchet power release of the power latch assembly, and the power release gear has a bi-directional rotation for emergency release. Background Art

[0004] This section provides background information related to closure latches and is not necessarily prior art to the closure latches of the present disclosure.

[0005] In view of the increased consumer demand for motor vehicles equipped with advanced comfort and convenience features, many current vehicles are now provided with power-actuated latch assemblies that are operable via a passive keyless entry system to allow for powered locking and powered release of the latch assembly without the use of a conventional manual entry mechanism. While such power-actuated latch assemblies provide the desired functionality under normal operating conditions, further improvements are needed to ensure that the features of the power-actuated latch assemblies achieve and maintain their intended position and function, including during emergency situations, such as crash situations, while also having a minimum of parts and being economical to manufacture.

[0006] In view of the foregoing, it remains desirable to develop alternative powered door latch assemblies that address and overcome the limitations associated with known powered door latch assemblies, thereby providing enhanced functionality while minimizing the cost and complexity associated with such advancements. Summary of the invention

[0007] This section provides a general summary of the disclosure and is not intended to be considered a comprehensive and exhaustive listing of its full scope or all of its aspects, features, and objects.

[0008] An aspect of the present disclosure is to provide a closure latch assembly for a vehicle closure panel, wherein the closure latch assembly has a minimal number of components and is economical to manufacture.

[0009] A closing latch assembly for a vehicle closing panel is provided. The closing latch assembly has: a power release gear, which is configured to be driven by a motor from an original position to a release position and back to the original position; and a latch mechanism, which includes a ratchet and a pawl. The ratchet can move between a primary striker capture position and a striker release position. The pawl can move between a ratchet holding position and a ratchet release position, in which the pawl holds the ratchet in the primary striker capture position and in which the pawl allows the ratchet to move to its striker release position. When the motor is energized in a first actuation, the power release gear is driven from the original position to the release position in a first direction, whereupon the power release gear operably drives the pawl from the ratchet holding position to the ratchet release position, so that the ratchet can move from the primary striker capture position to the striker release position. The motor drives the power release gear back to the original position in the first direction when the pawl is moved to the ratchet release position and the ratchet is moved from the primary striker capture position to the striker release position.

[0010] According to another aspect, the sensor is configured to send a signal to the motor to de-energize the motor when the power release gear returns to the original position.

[0011] According to another aspect, the ratchet stop lug is fixed to the ratchet and the power release gear stop lug is fixed to the power release gear, wherein, when the power release gear reaches the original position, in the absence of a signal from the sensor that the motor is powered off, the power release gear stop lug engages with the ratchet stop lug to prevent the power release gear from being driven beyond the original position.

[0012] According to another aspect, when the power release gear returns to the original position, the ratchet can return from the striker release position to the primary striker capture position, where the pawl returns to the ratchet holding position, without the sensor sending a signal to the motor to de-energize the motor.

[0013] According to another aspect, when the power release gear rotates from the original position in a first direction to the release position, without the pawl moving from the ratchet holding position to the ratchet release position and without the ratchet moving from the main striker pin capture position to the striker pin release position, the motor is energized in a second actuation to drive the power release gear in a second direction, whereupon the power release gear drives the pawl from the ratchet holding position to the ratchet release state in an operably manner, so that the ratchet moves from the main striker pin capture position to the striker pin release position.

[0014] According to another aspect, the power release gear exerts a first force on the pawl while rotating in a first direction and exerts a force on the pawl while rotating in a second direction, wherein the second force is greater than the first force.

[0015] According to another aspect, the power release gear rotates over a first degree range while rotating in a first direction, and the power release gear rotates over a second degree range while rotating in a second direction, wherein the second degree range is greater than the first degree range.

[0016] According to another aspect, when the power release gear rotates in the second direction to the release position, the motor is energized in a third actuation to drive the power release gear in the first direction for a second time without the pawl moving from the ratchet holding position to the ratchet release position and the ratchet moving from the main striker pin capture position to the striker pin release position.

[0017] According to another aspect, the power release gear rotates across a first degree range while rotating in a first direction during a first actuation, and rotates across a second degree range while rotating in a second direction, the second degree range being greater than the first degree range, and wherein the power release gear rotates across a third degree range while rotating in the first direction during a second actuation, the third degree range being equal to or greater than the second degree range.

[0018] According to another aspect, the power release gear applies a first force on the pawl while rotating in a first direction during a first actuation, and applies a second force on the pawl while rotating in a second direction, wherein the second force is greater than the first force, and the power release gear applies a third force on the pawl while rotating in the first direction during a second actuation, wherein the third force is equal to or greater than the second force.

[0019] According to another aspect, the motor is powered by the main power source during the first actuation and by the backup energy source during the second actuation.

[0020] According to another aspect, the motor is powered by the primary power source during the first actuation and by the backup power source during the third actuation.

[0021] According to another aspect, the motor is powered by the backup power source during the second actuation.

[0022] According to another aspect, a method of actuating a closing latch assembly under normal operating conditions and under emergency operating conditions is provided. The method includes: during the normal operating condition, in a first actuation, powering a motor to rotate a power release gear in a first direction, thereby operatively moving a pawl from a ratchet holding position to a ratchet release position, thereby moving the ratchet from a primary striker capture position to a striker release position. If the pawl fails to move from the ratchet holding position to the ratchet release position during the normal operating condition, then during the emergency operating condition, powering the motor in a second actuation to rotate the power release gear in a second direction opposite to the first direction, thereby operatively moving the pawl from the ratchet holding position to the ratchet release position, thereby moving the ratchet from the primary striker capture position to the striker release position.

[0023] According to another aspect, the method further includes applying a first force on the pawl while rotating the power release gear in a first direction; and applying a second force on the pawl while rotating the power release gear in a second direction, wherein the second force is greater than the first force.

[0024] According to another aspect, the method further includes rotating the power release gear across a first degree range while rotating in a first direction; and rotating the power release gear across a second degree range while rotating in a second direction, wherein the second degree range is greater than the first degree range.

[0025] According to another aspect, the method further includes, during an emergency operating condition, powering the motor in a third actuation after the second actuation to rotate the power release gear in a first direction to operably move the pawl from the ratchet holding position to the ratchet release position to move the ratchet from the primary striker pin capture position to the striker pin release position.

[0026] According to another aspect, the method also includes: causing the power release gear to apply a first force on the pawl while rotating in a first direction in response to a first actuation; and causing the power release gear to apply a second force on the pawl while rotating in a second direction in response to a second actuation, wherein the second force is greater than the first force; and causing the power release gear to apply a third force on the pawl while rotating in the first direction in response to a third actuation, wherein the third force is equal to or greater than the second force.

[0027] According to another aspect, the method further includes: rotating the power release gear across a first degree range while rotating in a first direction during a first actuation; and rotating the power release gear across a second degree range while rotating in a second direction, the second degree range being greater than the first degree range; and rotating the power release wheel across a third degree range while rotating in the first direction during a third actuation, the third degree range being equal to or greater than the second degree range.

[0028] According to another aspect, the method further includes powering the motor using the primary power source during normal operating conditions and powering the motor using the backup power source during emergency operating conditions.

[0029] Further areas of applicability will become apparent from the description provided herein.As stated above, the description and any specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The drawings described herein have been provided to illustrate selected embodiments and certain features thereof, and these drawings are not intended to limit the scope of the present disclosure. The present disclosure will now be described by way of example only with reference to the accompanying drawings, in which:

[0031] Figure 1 is a perspective view of a motor vehicle having a vehicle closure panel equipped with a closure latch assembly constructed in accordance with aspects of the present disclosure;

[0032] Figure 2 According to one aspect of the present disclosure Figure 1 A perspective view of a closure latch assembly of FIG. 1 showing a ratchet of the closure latch assembly in a primary striker captured position;

[0033] Figure 2A yes Figure 2 Exploded diagram of

[0034] Figure 3 is a perspective view of a ratchet illustrating a ratchet stop lug attached to the ratchet, wherein a power release gear has a power release gear stop lug configured to selectively engage with the ratchet stop lug;

[0035] Figure 4A is a front side view of the closed latch assembly in a latched position corresponding to the ratchet being in a primary striker captured position;

[0036] Figure 4B yes Figure 4A Rear view of

[0037] Figure 5A and Figure 5B Similar to Figure 4A and Figure 4B , which illustrates an initial stage in which a motor of a closing latch assembly is energized to drive a power release gear from a home position in a first direction to a release position and a pawl is driven from a ratchet holding position to a ratchet releasing position;

[0038] Fig. 6A and Figure 6B Respectively similar to Figure 5A and Figure 5B, which illustrates the initial stage of the ratchet being released to move from the primary striker capturing position to the striker releasing position;

[0039] Fig. 7A and Figure 7B Similar to Fig. 6A and Figure 6B , which illustrates the ratchet moving to the striker release position;

[0040] Fig. 8A and Figure 8B Similar to Fig. 7A and Figure 7B , which illustrates that the power release gear continues to rotate in the first direction toward the reset original position;

[0041] Fig. 9A and Fig. 9B Similar to Fig. 8A and Figure 8B , which illustrates that the sensor detects that the power release gear moves to a reset home position, wherein the sensor signals the motor to de-energize the motor, thereby stopping the power release gear from rotating;

[0042] Fig. 10A and Fig. 10B Similar to Fig. 8A and Figure 8B , which illustrates that in the event that the sensor does not send a signal to the motor to de-energize the motor due to a sensor failure, the power release gear moves to engage the power release gear stop lug with the ratchet stop lug, thereby holding the pawl in place to return to the ratchet holding position when the ratchet returns to the primary striker capture position;

[0043] Fig.11A and Fig. 11B Similar to Fig. 10A and Fig. 10B , which illustrates the ratchet returning to the primary striker capture position under the impact force of the striker, wherein the pawl returns to the ratchet holding position during a sensor failure;

[0044] Fig. 12A and Fig. 12B A release failure is illustrated in which the pawl is released from a ratchet holding position to a ratchet releasing position during a first normal operation;

[0045] Fig.13A and Fig. 13B illustrates a second release operation in an emergency operation, wherein a motor of a closing latch assembly is energized to drive a powered release gear in a second direction opposite to the first direction;

[0046] Fig.14A and Fig. 14BA third release operation is illustrated in an emergency operation, wherein a motor of a closing latch assembly is energized to drive a power release gear in a first direction opposite to a second direction; and

[0047] Fig.15 A flow chart of a method of actuating a closure latch assembly under normal operating conditions and emergency operating conditions according to another aspect of the present disclosure is illustrated. DETAILED DESCRIPTION

[0048] By way of example and not limitation, example embodiments of closing latch assemblies used in motor vehicle closing panels, such as doors, are provided so that the disclosure will be thorough and the scope will be fully conveyed to those skilled in the art. Many specific details such as examples of specific components, devices, and methods are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, and that the example embodiments may be implemented in many different forms, and none should be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known techniques are not described in detail.

[0049] The terms used herein are only used for the purpose of describing specific example embodiments and are not intended to be limiting. As used herein, the singular forms "a", "an", and "the" may also be intended to include the plural forms unless the context clearly indicates otherwise. The terms "comprises", "comprising", "including", and "having" are inclusive and therefore specify the presence of the features, wholes, steps, operations, elements, and / or parts described, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components, and / or groups thereof. Unless the order of execution is specifically indicated, the method steps, processes, and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or illustrated. It should also be understood that additional or alternative steps may be adopted.

[0050] When an element or layer is referred to as being "located on another element or layer," "engaged to," "connected to," or "coupled to" another element or layer, the element or layer may be directly located on, engaged to, connected to, or coupled to another element or layer, or there may be intermediate elements or layers. In contrast, when an element is referred to as being "directly located on another element or layer," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other words used to describe the relationship between elements (e.g., "located between" and "directly located between," "adjacent" and "directly adjacent," etc.) should be interpreted in a similar manner. As used herein, the term "and / or" includes any and all combinations of one or more items of the associated listed items.

[0051] Although the terms first, second, third, etc. can be used in this article to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or section from another region, layer or section. Unless the context clearly indicates, terms such as "first", "second" and other numerical terms do not mean order or sequence when used in this article. Therefore, without departing from the teaching of the example embodiments, the first element, component, region, layer or section discussed below can be referred to as the second element, component, region, layer or section.

[0052] For ease of description, spatially relative terms such as "inside", "outside", "below", "below", "lower", "above", "upper", "top", "bottom", etc. may be used herein to describe the relationship between one element or feature and another element or feature as illustrated in the figure. Spatially relative terms may be intended to cover different orientations of the device in use or operation other than the orientation depicted in the accompanying drawings. For example, if the device in the figure is turned over, the elements described as "below" or "below" other elements or features will be oriented "above" the other elements or features. Therefore, the example term "below" can cover both above and below orientations. The device can be oriented in other ways (rotated angles or in other orientations), and the spatially relative descriptions used herein are interpreted accordingly.

[0053] First refer to Figure 1A closure latch assembly for a motor vehicle closure panel, such as a swing door, shown by way of example and not limitation as a rear door 12, for a motor vehicle 14, also referred to as a closure latch or latch assembly 10, is shown positioned along a closing face portion 16 of the door 12 and is configured to releasably engage and capture a striker 18 secured to a vehicle body 22 to extend within a door opening 20 formed in the vehicle body 22 in response to the door 12 moving from an open position to a closed position. The door 12 is shown to include an outside door handle 24 and an inside door handle 26, both of which are operably (i.e., electrically and / or mechanically) connected to the closure latch assembly 10. Although not shown, it is understood that a similar closure latch assembly is provided in association with the front door 13 of the vehicle 14, which is shown to include its own outside door handle 25.

[0054] Now refer to Figures 2 to 5B , shows a non-limiting example embodiment of a closure latch assembly 10 and its internal components including a latch mechanism 31, wherein: Figure 2 1 and 10. The latch mechanism 31 of the closed latch assembly 10 is shown in the closed latch position. The latch mechanism 31 is shown having a ratchet 32 ​​and a pawl 36. The ratchet 32 ​​is pivotally mounted to a plate section of the latch housing, also referred to as the frame plate 28, and has a ratchet slot 34 that can be aligned with the fishmouth slot 30 formed in the frame plate 28. The ratchet 32 ​​can be in the main closed position or "strike catch" position ( Figure 2 , Figure 2A , FIG. 4A to FIG. 5B as well as FIG. 11A to FIG. 11B ) and the open or “strike release” position ( 7A to 10B ), in which the striker 18 is retained within the fishmouth slot 30 by being captured in the ratchet slot 34, and in an open or "strike release" position, the striker 18 is freely released from the ratchet slot 34 and the fishmouth slot 30. The ratchet 32 ​​is biased toward its striker release position by a ratchet biasing member 32a, such as a ratchet spring. The pawl 36 is pivotally supported for movement between a fixed ratchet holding position, also referred to as a "closed" position, in which the pawl 36 positions and holds the ratchet 32 ​​in its striker capturing position, and an unsecured ratchet release position, also referred to as an "open" position, in which the pawl 36 is positioned to allow the ratchet 32 ​​to move to its striker releasing position, such as under a bias imparted to the ratchet 32 ​​by a ratchet spring. A pawl biasing member 36a, such as a pawl spring, is operable to normally bias the pawl 36 toward its open position.

[0055] The latch release mechanism may include: a power actuator 38, such as an electric motor, the power actuator 38 including a motor shaft having a worm gear 40 fixed to the motor shaft; and a power release gear 42 driven by the worm gear 40 of the electric motor 38, the power release gear 42 being used to drive an actuator release rod 44 by engaging a cam member 41 fixed to the power release gear 42 - the actuator release rod 44 is also referred to as an actuator rod or a power release link or a release link - for rotating around a central axis A1 ( Figure 2A ) eccentrically rotates, wherein the cam member 41 is disposed in the receiving portion 44b ( Figure 2A ) in. The release link 44 is in turn used to drive a latch release lever 46 - the latch release lever 46 is shown as a pawl lever, also known as a release lever, which in turn drives the pawl 36 from its ratchet holding position to its ratchet release position to provide the power release function of the latch mechanism 31. The release lever 46 is shown as a pawl lever pin, also known as a follower pin 46a, as a driven feature fixed thereto, wherein the follower pin 46a is received through the elongated slot 44a of the release link 44 for lost motion therein. During movement of the release link 44 in response to movement of the power release gear 42 from the home position in the first direction D1, the follower pin 46a is drivingly engaged by the end of the slot 44a, so that the release lever 46a is driven to cause the pawl 36 to move from the ratchet holding position to the ratchet release position against the bias imparted by the pawl biasing member 36a.

[0056] The sensor 50, such as a Hall sensor, is configured to be in operative communication with the motor 38 to detect the home position of the power release gear 42, such as by detecting a magnet 51 fixed to the power release gear 42. The sensor 50 is in communication with a controller 54, which is configured to control the operation of the motor 38. According to a non-limiting example, the controller 54 can be a combination of hardware and / or software, such as implemented in the form of a microprocessor and other circuit arrangements or other electronic circuit arrangements. In operation, the power release gear 42 is configured to be driven by the motor 38 in a single direction, referred to as the first direction D1, during normal operation (when no increased load exceeding the expected or otherwise desired load is imparted in the entire latch mechanism 31 during normal use), rotate from a rest position, also referred to as the home position, to a release position, and then continue to rotate in the same first direction D1 to a reset position corresponding to the home position. Therefore, the power release gear 42 rotates only in the first direction D1 to perform the release and reset functions. During rotation in the first direction D1, the power release gear 42 rotates from the rest position to the release position over a first range of degrees, also referred to as the first distance d1. The power release gear 42 operatively (directly or indirectly through intermediate components, namely the actuator release lever 44 and the latch release lever 46) exerts a first force F1 on the pawl 36 while rotating in the first direction D1.

[0057] The ratchet has a ratchet stop lug 52 also known as a safety block feature. Figure 2A and Figure 3 , the ratchet stop lug 52 may be formed as a separate piece of material from the ratchet 32 ​​and subsequently secured to the ratchet 32. Additionally, where desired, it is contemplated herein that the ratchet stop lug 52 may be formed as an integral piece of material with the ratchet 32. Regardless, the ratchet stop lug 52 is secured to the ratchet 32 ​​for joint movement therewith.

[0058] In normal operation, the power release gear 42 is configured to be rotated by the motor 38 in a single first rotational direction D1 from a position also referred to as a home position ( Figure 4A and Figure 4B ) from the stationary position to the release position ( Figure 5A and Figure 5B ), in the rest position, the pawl 36 holds the ratchet 32 ​​in the primary striker capture position, and in the release position, the pawl 36 is intended to move to the ratchet release position against the bias imparted by the pawl biasing member 36a, and the ratchet 32 ​​is intended to move to the striker release position under the bias imparted by the ratchet biasing member 32a. Then, the power release gear 42 continues to move in the same first direction D1 ( FIG. 6A to FIG. 9B ) rotates back to its original position ( Fig. 9Aand Fig. 9B ) corresponding to the reset position. The power release gear 42 has a power release gear stop lug 48 fixed thereto - also known as a safety block feature - which is only used to function in the event of a failure of a sensor 50 configured to detect the return of the power release gear 42 to its original position. The sensor 50 is configured to send a signal to the motor 38 via the controller 54 to de-energize the motor 38 when the power release gear 42 reaches the original position. By way of example and not limitation, the sensor 50 can be configured to detect the position of a magnet 51 fixed to the power release gear 42, thereby enabling the sensor 50 to detect when the power release gear 42 is in a desired position, such as the original position, at which the sensor 50 sends a signal to the motor 38 to de-energize the motor 38.

[0059] In the event that the sensor 50 does not send a signal to the motor 38 to de-energize the motor 38 when the power release gear 42 returns from the release position to the home position, which may occur, for example, when the sensor 50 and / or the magnet 51 become inoperative, such as by becoming damaged, by way of example and not limitation, the power release gear stop lug 48 engages with the ratchet 32 ​​( Fig. 10B ) The ratchet stop lug 52 is fixed to prevent the power release gear 42 from being continuously driven in the first direction D1 beyond and away from the original position. Therefore, when the power release gear 42 remains in the original position, Fig.11A and Fig. 11B As shown in FIG, upon closing the vehicle closure panel 12, the ratchet 32 ​​remains free to return to the primary striker capture position, and the pawl 36 returns to the ratchet retaining position under the bias imparted by the pawl biasing member 36a. After the ratchet 32 ​​has returned to the fully closed position, as shown in FIG. Fig. 11B As shown in the figure, the ratchet stop lug 52 is moved out of the travel path of the power release gear stop lug 48, and when the motor 38 is subsequently activated in the direction D1, d1 to release the latch again, the power release gear 42 will not be blocked by the ratchet stop lug 52. Therefore, the latch 10 in one possible configuration is configured to have a one-way power release chain, wherein the rotation of the power release gear and the rotation of the motor 38 can be provided in a single direction illustratively shown as the direction D1, d1 during the normal mode (e.g., non-emergency mode). Therefore, there is no need for control of the motor 38, such as requiring an H-bridge, because the motor 38 is only controlled to provide an on / off power signal, rather than a reversal of the power supply polarity, thereby reducing electronic devices and control features. In addition, no return spring or return spring is required to return to the original position, and there is no need to drive the motor 38 back under the spring bias, thereby eliminating the spring component and the hard stop / impact reset noise caused by the return spring at each deactivation of the motor 38.

[0060] Furthermore, when the power release gear 42 rotates a first distance d1 in the first direction D1 during normal operation, the pawl 36 does not move from the ratchet holding position to the ratchet releasing position and the ratchet 32 ​​does not move from the primary striker capturing position to the striker releasing position ( Fig. 12A and 12B ), as mentioned above for Figure 5A and 5B As discussed, the controller 54 ( Figure 2 ) sends a signal to the motor 38 to energize the motor 38 so as to reverse the direction of rotation and move the power release gear 42 in a second direction D2 opposite to the first direction D1 ( Fig.13A During the rotation of the power release gear 42 in the second direction D2, the power release gear 42 operatively applies a second force F2 ( F2 ) on the pawl 36 (directly or indirectly through an intermediate component, namely, a release link, also referred to as an actuator release lever 44, and a release lever, also referred to as a latch release lever 46). Fig.13A ), thereby causing the pawl 36 to move from the ratchet holding position to the ratchet releasing position against the bias imparted by the pawl biasing member 36a, so that the ratchet 32 ​​moves from the main striker capturing position to the striker releasing position under the bias imparted by the ratchet biasing member 32a. It can be determined that when the power release gear 42 rotates in the first direction D1 during normal operation ( Fig. 12A and Fig. 12B ), the pawl 36 does not move from the ratchet holding position to the ratchet release position and the ratchet 32 ​​does not move from the primary striker capture position to the striker release position, such as by the sensor 50 not detecting that the power release gear 42 returns to the original position after the motor 38 is energized, and / or by the sensor not detecting that the position of the pawl 36 has moved to the ratchet release position, and / or by the sensor not detecting that the ratchet 32 ​​has rotated to the open striker release position, and / or by the sensor detecting that the motor 38 is in a stalled state. During rotation in the second direction D2, the power release gear 42 rotates from the rest position to the release position over a second range of degrees, also referred to as a second distance d2, wherein the second distance d2 is greater than the first distance d1. In the case where the second distance d2 is greater than the first distance d1, the second force F2 is greater than the first force F1, thereby overcoming the force F2 generated by the second force F2 generated by the second force F1. Fig. 12A and Fig. 12BThe resistance to the intended release of the closed latch assembly 10 during the first normal release attempt of the power release gear 42 is shown in FIG. 4 . The increased distance d2 traveled by the power release gear 42 causes an increase in inertia, which at least partially contributes to the increase in the second force F2 relative to the first force F1. In order to increase the travel distance of the power release gear 42 during motor reverse operation, such as may occur during emergency operation, the signal from the sensor 50 may be ignored by the controller 54 so as not to stop the power release gear 42 from rotating at the original position, so as to allow the power release gear 42 to fully develop rotational speed and inertia from its previous stopped position, such as at the stalled position.

[0061] For any reason, the closing latch assembly 10 is completed Fig.13A and Fig. 13B Whether the motor 38 remains in its latched state after the second actuation depicted in FIG. 5 , which can be easily determined by the aforementioned position detection sensor and controller 54 , a third actuation of the motor 38 can be performed via a signal from the sensor 50 . Fig.14A and Fig. 14B As shown in , the third actuation causes the motor 38 to reverse again to rotate in the first direction D1, whereupon the power release gear 42 applies a third force F3 on the pawl 36 in an operative manner (directly or indirectly through intermediate components, namely the actuator release lever 44 and the latch release lever 46), thereby moving the pawl 36 from the ratchet holding position to the ratchet release position, causing the ratchet 32 ​​to move from the primary striker capture position to the striker release position. During rotation in the first direction D1, the power release gear 42 rotates from the stationary position to the release position over a third degree range, also referred to as a third distance d3, wherein the third distance d3 is greater than the first distance d1 and is at least the same as or preferably greater than the second distance d2. In the event that the third distance d3 is greater than the first distance d1 and equal to or greater than the second distance d2, the third force F3 is greater than the first force F1 and equal to or greater than the second force F2, thereby maximizing the chances of overcoming the force F2 in the first direction D1. Fig. 12A and 12B The resistance during the normal release of the closed latch assembly 10 that prevents the intended release. The increased distance d3 traveled by the power release gear 42 causes an increase in inertia, which at least partially contributes to the increase of the third force F3 relative to the first force F1 and is desirably greater than the second force F2.

[0062] According to another aspect, in an emergency situation, the power used to power the motor 38 to drive the power release gear 42 during the second and third actuations can be provided by a backup power source 56 in addition to the main vehicle battery used during normal operation, which is also referred to as the main power source. The backup power source 56 can be provided as a fully charged supercapacitor, thereby having fully charged power, which may not be available from the main vehicle battery, especially in an emergency situation, such as a crash situation. As required, the backup power source 56 can be arranged to be in operative communication with the sensor 50 and / or the vehicle ECU 54.

[0063] exist Fig.15 , a flow chart illustrates a method 1000 for actuating a closure latch assembly 10 under normal operating conditions and under emergency operating conditions according to another aspect of the present disclosure. The method 1000 includes a step 1100 of actuating the closure latch assembly 10 in a normal mode, as discussed above and as described above. Fig. 12A and Fig. 12B During the normal operation mode, the motor 38 is powered to rotate in a single direction at step 1200, thereby rotating the power release gear 42 in a first direction D1 by a first distance D1, thereby imparting a first force F1 throughout the latch mechanism 31. Then, if the sensor 50 detects an emergency situation, such as a collision situation, at step 1300, the latch mechanism 31 remains in the latched state, as discussed above and as described in Fig.13A and Fig. 13B As shown in , step 1400 of actuating the closing latch assembly 10 in the emergency mode is performed, whereupon at step 1500 the motor 38 is rotated in the second direction, thereby driving the power release gear 42 a second distance d2 in the second direction D2, thereby imparting a second force F2 on the entire latch mechanism 31. The second distance d2 is greater than the first distance d1, and therefore, at least in part due to the increase in inertia, the second force F2 is greater than the first force F1. The next step 1600 determines whether the closing latch assembly 10 moves from the latched state to the unlatched state. If, for example, it is detected via the sensor 50 that the closing latch assembly 10 remains in the latched state, step 1700 is performed, in which the motor 38 is powered to rotate in the first direction ( Fig.14A and 14B) is rotated, thereby rotating the power release gear 42 in the first direction D1 by a third distance d3, thereby imparting a third force F3 in the entire latch mechanism 31, wherein the third force F3 is equal to or greater than the second force F2. The next step 1800 determines whether the closing latch assembly 10 moves from the latched state to the unlatched state. If, for example, it is detected via the sensor 50 that the closing latch assembly 10 remains in the latched state, step 1900 returns to step 1500 to repeat its operation, and step 1900 can continue until the closing latch assembly 10 is unlatched.

[0064] The foregoing description of the embodiments has been provided for the purpose of illustration and description. The foregoing description is not intended to be exhaustive or to limit the present disclosure. Each element or feature of a particular embodiment is generally not limited to the particular embodiment, but is interchangeable and can be used for a selected embodiment where applicable, even if not specifically shown or described. Each element or feature of a particular embodiment may also be changed in many ways. Such variations are not considered to be out of the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

[0065] The present disclosure can also be understood from the following paragraphs:

[0066] 1. A closure latch assembly for a vehicle closure panel, comprising:

[0067] motor;

[0068] a power release gear configured to be driven by the motor from an original position to a release position and back to the original position; and

[0069] a latch mechanism comprising a ratchet and a pawl, wherein the ratchet is movable between a primary striker capture position and a striker release position, wherein the pawl is movable between a ratchet holding position and a ratchet release position, wherein the pawl holds the ratchet in the primary striker capture position and wherein the pawl allows the ratchet to move to a ratchet striker release position.

[0070] wherein the motor, when energized in a first actuation, drives the power release gear from the original position in a first direction to the release position, whereupon the power release gear operably drives the pawl from the ratchet holding position to the ratchet release position, so that the ratchet can move from the primary striker capture position to the striker release position,

[0071] Wherein, the motor drives the power release gear back to the original position in the first direction when the pawl moves to the ratchet release position and the ratchet moves from the primary striker capture position to the striker release position.

[0072] 2. The closure latch assembly of paragraph 1, further comprising a sensor configured to send a signal to the motor to de-energize the motor when the power release gear returns to the original position.

[0073] 3. The closing latch assembly according to paragraph 2 further includes a ratchet stop lug fixed to the ratchet and a power release gear stop lug fixed to the power release gear, wherein, when the power release gear reaches the original position, the power release gear stop lug engages with the ratchet stop lug to prevent the power release gear from being driven beyond the original position without the sensor sending a signal to the motor to cut off power to the motor.

[0074] 4. A closed latch assembly according to paragraph 3, wherein when the power release gear reaches the original position, the ratchet is able to return from the striker release position to the main striker capture position without the sensor sending a signal to the motor to power off the motor, and at the main striker capture position, the pawl returns to the ratchet holding position.

[0075] 5. A closed latch assembly according to paragraph 1, wherein, when the power release gear rotates from the original position in the first direction to the release position, without the pawl moving from the ratchet holding position to the ratchet release position and without the ratchet moving from the main strike pin capture position to the strike pin release position, the motor is energized in a second actuation to drive the power release gear in a second direction, whereupon the power release gear drives the pawl from the ratchet holding position to the ratchet release position in an operably manner, causing the ratchet to move from the main strike pin capture position to the strike pin release position.

[0076] 6. A closing latch assembly according to paragraph 5, wherein the power release gear applies a first force on the pawl while rotating in the first direction, and applies a second force on the pawl while rotating in the second direction, and the second force is greater than the first force.

[0077] 7. A closing latch assembly according to paragraph 5, wherein the power release gear rotates through a first degree range while rotating in the first direction and rotates through a second degree range while rotating in the second direction, the second degree range being greater than the first degree range.

[0078] 8. A closed latch assembly according to paragraph 5, wherein, when the power release gear rotates in the second direction, the motor is energized in a third actuation to drive the power release gear in the first direction for a second time without the pawl moving from the ratchet holding position to the ratchet release position and the ratchet moving from the main striker pin capture position to the striker pin release position.

[0079] 9. A closed latch assembly according to paragraph 8, wherein the power release gear rotates across a first degree range while rotating in the first direction during the first actuation, and rotates across a second degree range while rotating in the second direction, the second degree range being greater than the first degree range, and wherein the power release gear rotates across a third degree range while rotating in the first direction during the second actuation, the third degree range being equal to or greater than the second degree range.

[0080] 10. A closed latch assembly according to paragraph 9, wherein the power release gear applies a first force on the pawl while rotating in the first direction during the first actuation, and applies a second force on the pawl while rotating in the second direction, the second force being greater than the first force, and the power release gear applies a third force on the pawl while rotating in the first direction during the second actuation, the third force being equal to or greater than the second force.

[0081] 11. The closure latch assembly of paragraph 5, wherein the motor is powered by a primary power source during the first actuation and is powered by a backup energy source during the second actuation.

[0082] 12. The closure latch assembly of paragraph 8, wherein the motor is powered by a primary power source during the first actuation and is powered by a backup power source during the third actuation.

[0083] 13. The closure latch assembly of paragraph 12, wherein the motor is powered by the backup power source during the second actuation.

[0084] 14. A method of actuating a closure latch assembly under normal operating conditions and emergency operating conditions, comprising:

[0085] during said normal operating condition, in a first actuation, powering the motor to rotate the power release gear in a first direction to operatively move the pawl from a ratchet holding position to a ratchet releasing position to move the ratchet from a primary striker capturing position to a striker releasing position, and if the pawl fails to move from said ratchet holding position to said ratchet releasing position;

[0086] During the emergency operating condition, the motor is powered in a second actuation to rotate the power release gear in a second direction, thereby operably moving the pawl from the ratchet holding position to the ratchet releasing position to move the ratchet from the primary striker capture position to the striker release position.

[0087] 15. The method according to paragraph 14 further includes causing the power release gear to apply a first force on the pawl while rotating in the first direction, and causing the power release gear to apply a second force on the pawl while rotating in the second direction, the second force being greater than the first force.

[0088] 16. The method of paragraph 14 further comprising rotating the power release gear across a first degree range while rotating in the first direction, and rotating the power release gear across a second degree range while rotating in the second direction, the second degree range being greater than the first degree range.

[0089] 17. The method according to paragraph 14 further includes, during the emergency operating condition, supplying power to the motor in a third actuation subsequent to the second actuation so that the power release gear rotates in the first direction, thereby operably moving the pawl from the ratchet holding position to the ratchet release position so that the ratchet moves from the main striker pin capture position to the striker pin release position.

[0090] 18. The method according to paragraph 17 also includes: causing the power release gear to apply a first force on the pawl while rotating along the first direction in response to the first actuation; and causing the power release gear to apply a second force on the pawl while rotating along the second direction in response to the second actuation, the second force being greater than the first force; and causing the power release gear to apply a third force on the pawl while rotating along the first direction in response to the third actuation, the third force being equal to or greater than the second force.

[0091] 19. The method according to paragraph 17 also includes: causing the power release gear to rotate across a first degree range while rotating in the first direction during the first actuation, and causing the power release gear to rotate across a second degree range while rotating in the second direction, the second degree range being greater than the first degree range, and causing the power release gear to rotate across a third degree range while rotating in the first direction during the third actuation, the third degree range being equal to or greater than the second degree range.

[0092] 20. The method of paragraph 14 further comprising powering the motor with a primary power source during the normal operating condition and powering the motor with a backup power source during the emergency operating condition.

Claims

1. A closure latch assembly (10) for a vehicle closure panel (12), comprising: Motor (38); a power release gear (42), the power release gear (42) being configured to be driven by the motor (38) from an original position to a release position and back to the original position; as well as A latch mechanism (31), the latch mechanism (31) comprising a ratchet (32) and a pawl (36), the ratchet (32) being movable between a primary striker pin capturing position and a striker pin releasing position, the pawl (36) being movable between a ratchet holding position and a ratchet releasing position, in which the pawl (36) holds the ratchet (32) in the primary striker pin capturing position, and in which the pawl (36) allows the ratchet (32) to move to the striker pin releasing position of the ratchet (32), wherein, when the motor (38) is energized in the first actuation, the power release gear (42) is driven from the original position to the release position in the first direction (D1), whereby the power release gear (42) operably drives the pawl (36) from the ratchet holding position to the ratchet release position, so that the ratchet (32) can move from the main striker capture position to the striker release position, The motor (38) drives the power release gear (42) back to the original position in the first direction when moving the pawl (36) to the ratchet release position and moving the ratchet (32) from the primary striker capture position to the striker release position.

2. The closing latch assembly (10) according to claim 1 further includes a sensor (50), wherein the sensor (50) is configured to send a signal to the motor (38) to de-energize the motor (38) when the power release gear (42) returns to the original position.

3. The closure latch assembly (10) of claim 2, further comprising a ratchet stop lug (52) fixed to the ratchet (32) and a power release gear stop lug (48) fixed to the power release gear (42), wherein: When the power release gear (42) reaches the original position, without the sensor (50) sending a signal to the motor (38) to cut off power to the motor (38), the power release gear stop lug (48) engages with the ratchet stop lug (52) to prevent the power release gear (41) from being driven beyond the original position.

4. The closure latch assembly (10) according to claim 3, wherein: When the power release gear (42) reaches the original position, the ratchet (32) is able to return from the striker release position to the primary striker capture position without the sensor (50) sending a signal to the motor (38) to de-energize the motor (38), and at the primary striker capture position, the pawl (36) returns to the ratchet holding position.

5. The closure latch assembly (10) of claim 1, wherein: When the power release gear (42) rotates from the original position along the first direction (D1) to the release position, without the pawl (36) moving from the ratchet holding position to the ratchet release position and without the ratchet (32) moving from the main striker pin capture position to the striker pin release position, the motor (38) is energized in the second actuation to drive the power release gear along the second direction (D2), whereupon the power release gear (42) drives the pawl (36) from the ratchet holding position to the ratchet release position in an operably manner, so that the ratchet (32) moves from the main striker pin capture position to the striker pin release position.

6. The closure latch assembly (10) according to claim 5, wherein: The power release gear (42) applies a first force (F1) on the pawl (36) while rotating in the first direction (D1), and applies a second force (F2) on the pawl (36) while rotating in the second direction (D2), wherein the second force (F2) is greater than the first force (F1).

7. The closure latch assembly (10) according to claim 5, wherein: The power release gear (42) rotates over a first degree range while rotating in the first direction (D1), and rotates over a second degree range while rotating in the second direction (D2), the second degree range being greater than the first degree range.

8. The closure latch assembly (10) according to claim 5, wherein: When the power release gear (42) rotates in the second direction (D2), the motor (38) is energized in a third actuation to drive the power release gear (42) in the first direction (D1) for a second time without the pawl (36) moving from the ratchet holding position to the ratchet releasing position and without the ratchet (32) moving from the primary striker pin capturing position to the striker pin releasing position.

9. The closure latch assembly (10) according to claim 8, wherein: The power release gear (42) rotates across a first degree range while rotating in the first direction (D1) during the first actuation, and rotates across a second degree range while rotating in the second direction (D2), the second degree range being greater than the first degree range, and wherein the power release gear (42) rotates across a third degree range while rotating in the first direction (D1) during the second actuation, the third degree range being equal to or greater than the second degree range.

10. The closure latch assembly (10) according to claim 9, wherein: The power release gear (42) applies a first force (F1) on the pawl (36) while rotating along the first direction (D1) during the first actuation, and applies a second force (F2) on the pawl (36) while rotating along the second direction (D2), the second force (F2) being greater than the first force (F1), and the power release gear (42) applies a third force (F3) on the pawl (36) while rotating along the first direction (D1) during the second actuation, the third force (F3) being equal to or greater than the second force (F2).

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